How Rhenus Achieved 100% Productivity Boost with AutoStore

Rhenus is a leading global logistics provider operating across 1,330 sites in more than 70 countries, with extensive experience in warehousing and managing complex supply chains. For over 20 years, Rhenus has been working closely with Thalia, the leading omni-channel bookseller in Germany, Austria, and Switzerland.

Thalia faced increasing demands for improved speed and efficiency from its extensive retail network and growing e-commerce channel. In collaboration with Rhenus, Thalia was looking for a solution that could scale with its business.

Rhenus implemented an AutoStore automated storage and fulfillment system, empowered by AutoStore partner Kardex, for Thalia’s requirements at its Hörselgau site in Germany. The automated high-density system significantly improved their productivity and fulfillment capacity.

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The Challenge: Keeping Up With Growing Demand

Rhenus’ existing manual processes struggled to keep up with the demands that came from serving Thalia’s hundreds of physical stores and meeting rising e-commerce demand. The company needed to improve order accuracy, reduce processing times, and utilize warehouse space more efficiently. Rhenus also wanted enough flexibility to accommodate future growth. Training new employees for peak seasons also presented significant time and resource challenges.

The Solution: AutoStore’s Automated Warehousing

AutoStore's system provided Rhenus with high-density storage and autonomous Robots for efficient order retrieval. Within a footprint of only 8,000 m² (86,112ft²), the system houses 530 R5 Robots, 94 CarouselPorts (Workstations), 240,000 storage Bins, and a 2.5 km conveyor system. All components are seamlessly integrated with Rhenus's warehouse management system.

The system operates through a grid-based approach. Goods are stored in stacked Bins within an aluminum framework called the Grid. Robots move across the top of the Grid, retrieving Bins as needed by lifting them to the surface. These Robots then deliver the Bins to designated workstations, where items are picked or replenished.

Key Benefits: Productivity, Speed, and Scalability

The automated system delivered substantial improvements in warehouse operations, enabling them to handle significantly more orders without expanding their workforce or warehouse footprint. Order accuracy and reliability have improved.

• 100% productivity increase enabling higher order volumes
• 75% faster training for new staff
• Space optimization with 240,000 Bins in 8,000m² (86,112ft²)
• Reduced errors through automated processes
• Scalable design for future expansion

Simon Ölscher, Senior Sales Manager at Kardex, celebrates the success: “This is really one of the AutoStore systems with the highest throughput worldwide.”

Set For Growth

Rhenus’ investment in AutoStore has created a solid foundation for continued growth with Rhenus’ Managing Director of Warehousing Solutions Germany, René Rudolph, stating, “The AutoStore system is a central component of our future warehousing approach.” The system's adaptable design can accommodate new store openings, seasonal demand fluctuations, and evolving e-commerce requirements.

Project Specifications

• Implementation type: Brownfield
• Robots: 530 R5 Robots, 1 Bin ResQ Robot
• Workstations (Ports): 94 CarouselPorts
• Bins: 240,000 Bins
• Integrated technology: KCC Software; IPA Picking Assistant; 2.5km Conveyor System

Integration partner: Kardex